SAVITA INTERNATIONAL - AHMEDABAD

INDUCTION FURNACE VS ARC FURNACE POWER

INDUCTION FURNACE ARC FURNACE POWER
  • 30 MT/12.5 MW induction furnace of 2 Nos.  25 MVA with production of 960-1000 MT per day in practical.
  • 35 MT LRF can be used.
  • Power consumption will be 525 Kwh/ MT. No Oxygen lancing is required.
  • Being Static load power factor remains 0.94 to 0.97
  • MDI demand 40% less compared to arc furnace for same production.
  • Being study load no consideration of fault level
  • No problem for any connection. Power station are enough capacity for induction furnace
  • Induction load is steady and without any fluctuation.
  • Due to 12 pulse harmonics distortion level will be comparatively very low. Small capacity of harmonics filter may require. Even need not for Harmonic filters.
  • In Induction furnace no electrode is used
  • For 60 tonne electric arc furnace require 40 MVA with production of 840-900 MT per day in practical.
  • 70 MT LRF is required.
  • Power consumption will be minimum 600 Kwh / MT plus 20 Oxygen / Ton
  • Power factor will vary from 0.75 to 0.80 and to be increased by capacitor bank to 0.92 at extra cost.
  • MDI demand will be 1.5 than Induction furnace as compared to production.
  • The fault level in Arc furnace will be around minimum 50 times means power substation should be of 2000 MVA capacity
  • Generally Saudi Arabia power station are not strong to provide connection for more than 20 MVA arc furnace due to fault level
  • There is to too much flickering, power fluctuation affecting the substation and power lines.
  • In arc furnace the harmonics level is high and not acceptable to electricity board and you have to provide harmonics filter
  • Electrode consumption in arc furnace is around 4 Kg per MT costing around US$15 per tonne

PRODUCTION

  • Production will be around 960-1000 MT per day
  • Production will be around 840-900 MT per day

REFRACTORY

  • Acidic ramming mass (Silica quartz) is used and the per tonne cost is 1/4 of arc furnace
  • High Alumina and Magnesite ramming mass and bricks are used in lining
BURNING LOSES
  • If similar scrap is used burning loss is not more than 5% to 6 %
  • In arc furnace burning loss is 10 %
FERRO ALLOYS
  • Ferro Alloy consumption is about 70% due to calculated charge mixes compare to arc furnace.
  • Due to slag making technology and oxidation Ferro alloys consumption is high.
OXYGEN LANCING
  • Oxygen lancing is not required
  • In arc furnace oxygen gas lancing is must.
QUALITY
  • We can manufacture all types of alloy comparable to arc furnace. There is no problem for any alloys. Alloy steel can be manufactured with calculated charge and with help of LRF.
  • Alloy steels can be manufactured to micro control to chemical composition
MAINTENANCE
  • Maintenance is around 30% as compared to arc furnace due to non moving parts and electronics base.
  • Maintenance cost in arc furnace is very high, minimum 3 times than induction furnace due to too much mechanical and electrical system
SKILLED PEOPLE
  • In induction furnace a few skilled technical personnel is required.
  • In arc furnace skilled people’s team of mechanical, electrical & metallurgical is required. Costing double than induction
LABOUR
  • Labour cost is low as 70% of arc furnace
  • Labour cost is high
CAPITAL SPACE & AREA
  • Induction furnace is a compact furnace and required about half area as compare to arc furnace.
  • In arc furnace three times area is required due to high volume and area of the furnace as induction furnace
LRF
  • 35 MT LRF is required for minor composition adjustment.
  • 70 MT LRF is must for arc furnace for composition control.
CAPITAL INVESTMENT
  • In case of induction furnace capital investment will be around 50% of arc furnace
  • Capital investment required in arc furnace is 3 times the induction furnace due to high cost of plant and machinery infrastructure cost, area requirements.

Considering the above points arc furnaces are internationally not viable & not operating where tariff is difficult and power is high. This is the basic reason in India where around 450 arc furnaces were working and 90% are converted into induction furnace. While in other developed countries second hand arc furnaces up to 100 metric tonne is easily available for same. First point is to lookout electric fault level

You may please ask for future clarifications. We will like to give more information.

INDUCTION FURNACE   VS  ARC FURNACE POWER

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